Refractory shape with embedded channel shape reinforcement



Nov. 15, 1966 R. A. EDWARDS REFRACTORY SHAPE WITH EMBEDDED CHANNEL SHAPE REINFORCEMENT Filed NOV. 6, 1963 United States Patent 3,284.97 9 REFRACTORY SHAPE WITH EMBEDDED CHANNEL SHAPE REINFORCEMENT Robert A. Edwards, Columbiana, Ohio, assignor to Kaiser Aluminum & Chemical Corporation, Oakland, Calif.,

a corporation of Delaware Filed Nov. 6, 1963, Ser. No. 321,897 Claims. (Cl. 52-600) This invention relates to internally reinforced refractory brick and to metal elements for use therein.

It is well known to form refractory shapes, particularly shapes composed of nonacid refractory material including magnesite, periclase, and mixtures of these with chromite, with internal metal reinforcement. One common form which such internal reinforcement takes is the so-called U-core. These reinforcing cores are generally made from a sheet of plain carbon steel of a thickness from about 5 inch to inch. The sheet is bent, generally parallel to its longest dimension, into the form of a channel having a back or web (corresponding to the base of the U) and two side flanges disposed at opposite edges of the web. It is a general practice to insert these U-cores into the refractory shape so that the web or base of the U lies in the plane of one exterior longitudinal face of the shape and the two side flanges are embedded in the refractory material. Such an assembly may be made by co-molding, i.e., inserting the metal reinforcement into the refractory material at the time such material is pressed in-to a brick or other shape.

Although a very large number of refractory brick have been made by the above co-molding process with internal U-c-ore reinforcements, there are disadvantages to the prior art structure. Because of the high pressures involved in the molding process, there is strain and distortion of the U-core during its insertion or pressing into the refractory material. The release of the pressure upon removal of the formed shape from the press results in a change in shape of the internal reinforcement. This change in shape of the metal reinforcement leads to stresses in the refractory shape and may even cause cracking of the shape along the edge of the reinforcement. Even where no exterior cracks are evident, the refractory shape is greatly weakened by the internal stresses.

An even more readily apparent shortcoming of the prior art oo-molded U-core shapes is that they (apparently due to the stresses in the metal reinforcement and the brick) show a taper from one face to the other, being wider on the face wherein lies the exposed back or web of the U-core reinforcement. This taper, which amounts to several thousandths of an inch, becomes very serious when a number of such refractory shapes are assembled to form a furnace wall or root. In fact, so serious has this taper been in the past that it has frequently been necessary to lay up .a furnace wall or roof with such shapes in alternating relationship in order to get a straight structure. Otherwise, a curvature or bend occurs in the wall or roof, due to the taper'of the individual units.

According to the present invention, there has now been 'iscovered a form of U-core metal reinforcement for refractory shapes which over-comes in large part the above disadvantages and results in a refractory shape with greater strength, less tendency to crack, and showing considerably less taper than prior art U-co-re brick.

In the annexed drawing:

FIGURE 1 is a perspective view of a U-core metal reinforcement for use in a refractory shape according to this invention;

FIGURE 2 is a plan view of a refractory brick having a reinforcement according to this invention; and

3,284,979 Patented Nov. 15, 1966 "ice FIGURE 3 is a cross-sectional view taken along the line 3-3 of FIGURE 2.

A U-core metal reinforcement 10 according to this invention comprises an elongated metal channel having a generally rectangular web 11 with two opposed long edges 26 and 26 and two short end edges 27 and 2-7 and two generally rectangular side flanges 12 and 12' having .free outer edges 21 and 21 and inner edges 26 and 26' attached to the web. However, in the reinforcement of this invention there are struck from each side flange 12 of the U-core reinforcement one or more arms 13, these arms comprising a base 14 which lies substantially in the Iplane of the web 11 and for-ms an extension thereof and a shoulder 15 which is disposed substantially perpendicularly to the base 14 and extends substantially parallel to and in the same direction as the side flanges 12 and 12 of the U or channel.

Although the embodiment of FIGURE 1 is shown with three such arms 13 on either side of the main U-core, it will be understood that, alternatively, either a greater or lesser number of arms can be used. It will also be understood that other arrangements, such as a staggered arrangement, of the arms can be 'used on either side. Furthermore, the arms can vary in size or dimensions. Preferably, the side flanges 12 will be substantially perpendicular to the back 11 and the shoulders 15 of the arms 13 will be substantially perpendicular to the bases 14 of the arms, but other angles can be used.

The reinforcement 10 is inserted in a refractory shape 17, for example by co-molding, so that the web 11 of the U-shape and the bases 14 of the arms 13 lie in the plane of one face 18 of the refractory shape, so as to be visible on the surface. The side flanges 12 of the U-shaped reinforcement and the shoulders 15 of the arms 13 Struck from the sides 12 and 12' extend down into the refractory shape 17, anchoring the metal reinforcement to the refractory and strengthening the refractory shape itself. Also, refractory material extends through the openings 16 in side flanges 12, 12 in the embodiment where the side flanges 13, 13 are struck therefrom, further aiding in anchoring the channel firmly in the -r fraotory shape. It is frequently desirable to have. the metal reinforcement extend from one end :face 20 of the refractory shape to the opposite end face 20, but the reinforcement can be terminated short of either or both end faces 20, 20 as shown in FIGURE 2. Generally the side flanges 12 and 12' of the metal reinforcement will not extend completely through the refractory shape 17 to the face 18 opposite the face 18 containing the plane of the web :11 of the metal reinforcement. However, the side flanges 12 can extend through to the face 18 of the refractory shape, if desired.

The arms 13, are preferably of shorter length than side flanges 12, 12', especially when struck therefrom, whereby the openings or apertures 16, are enclosed or surrounded on all sides by metal of side flanges 12, 12'. However, if desired, the arms 13 can be as long or longer than side flanges 12, 12'. In such embodiments the apertures remaining if side arms 13 are struck out are enclosed or bounded by metal on three sides only or are open to provide an interrupted edge of side flange 12, for example, remote from web 11. Also, it will generally be desired that the shoulders 15 of the arms 13 lie, when embedded in the refractory shape 17, totally within the refractory and not on the side faces 19 and 19 of the refractory shape. However, again it may be desirable in some instances to make the shape with these shoulders 15 in the plane of the sides 19 and 19.

When it is said that the plane of the web 11 and of the bases 14 of the arms 13 lie in the plane of the face 18 of the refractory or that the planes of the shoulders 3 15 lie in the plane of the side faces 19 and 19', it will be understood that the exposed surface of the metal is flush with the surface of the refractory, the metal being embedded in the refractory to the extent of the thickness of the sheet from which the metal reinforcement is made.

As an example of the superior results obtained with the metal reinforcement of this invention, standard 9x4 /2x3 /z refractory shapes were pressed from a standard basic refractory mix, the U-core reinforcement being co-molded or pressed into the refractory mix at the time the shapes were formed so that the web of the U-core reinforcements lay in the plane of one 9x4 /2 inch face. Bricks made with conventional U-cores showed a taper of 0.042 inch (measured across the 4 /2 inch dimension of the face), whereas bricks made with reinforcements according to this invention showed an average taper of only 0.007 inch measured in the same way.

It will be understood that the above specific description has been given for purpose of illustration only. For instance, instead of struck-out arms 13, such elements can be atfixed to the web 11 of channel 10 by welding or as otherwise desired. However, this is a more expensive and troublesome procedure; and it is a further advantage of the provision of struck-out arms, such as 13, that the refractory material extends through the openings or apertures left thereby, strengthening the final product, as described hereinabove. It will also be understood that the sides of the channel need not be exactly perpendicular to web of the U-core reinforcement, nor need Having now described the invention, what is claimed 1s:

1. A nonacid refractory shape having a flat surface and a metal reinforcement comprising:

(a) a generally U-shaped channel having (b) a flat web and (c) two side flanges, and

(d) a plurality of arms extending outwardly from said web and struck from said flanges, each of said arms having (e) a flat base lying in the plane of the web, and

(f) a shoulder disposed in the same direction as the flanges, the plane of the web of the metal reinforcement lying in the plane of the flat surface of the refractory shape, and the flanges of the U-shaped channel and the shoulders of the arms being embedded in the refractory shape.

2. A nonacid refractory shape having a first flat surface, a second and flat surface substantially at right angles to the first flat surface and a metal reinforcement comprising:

(a) a generally U-shaped channel having (b) a flat web and two side flanges, and

(d) a plurality of arms extending outwardly from said web and struck from said flanges, each of said arms having (e) a flat base lying in the plane of the web, and

(f) a shoulder disposed in the same direction as the flanges, the plane of the web of the metal reinforcement lying in the plane of the first flat surface of the refractory shape, the side flanges of the -shaped channel being embedded shape, and the shoulder of at least one arm lying in the plane of the second flat surface.

3. A nonacid refractory shape having a flat surface and a metal reinforcement comprising:

(a) a generally U-shaped channel having (b) a flat web and (c) two parallel side flanges substantially perpendicular thereto, and

(d) a plurality of arms extending outwardly from said web and struck from said flanges, each of said arms having (e) a flat base lying in the plane of the web, and

(f) a shoulder disposed in the same direction as the flanges,

the plane of the web of the metal reinforcement lying in the plane of the flat surface of the refractory shape, and the side flanges of the U-shaped channel and the shoulders of the arms being embedded in the refractory shape.

4. A nonacid refractory shape having a flat surface and a metal reinforcement comprising:

(a) a generally U-shaped channel having (b) a flat web and (c) 2 parallel side thereto, and

(d) a plurality of arms extending outwardly from said web and struck from said flanges, each of said arms having (e) a flat base lying in the plane of the web, and

(f) a shoulder disposed substantially perpendicular to the base and extending in the same direction as the flanges,

the plane of the web of the metal reinformecent lying in the plane of the flat surface of the refractory shape, and the side flanges of the U-shaped channel and the shoulders of the arms being embedded in the refractory shape.

5. A nonacid refractory shape having a flat surface and a metal reinforcement comprising:

(a) a generally U-shaped channel having (b) a flat web and (0) two side flanges joined to the web at opposite sides thereof, each of said flanges having an inner edge joined to said web and an uninterrupted outer edge, and

(d) a plurality of arms extending outwardly from said web and struck from said flanges, each of said arms having (e) a flat base lying in the plane of the web and (f) a shoulder disposed in the same direction as the flanges,

the plane of the web of the metal reinforcement lying in the plane of the flat surface of the refractory shape, and the side flanges of the U-shaped channel and the shoulders of the arms being embedded in the refractory shape.

in the refractory flanges substantially perpendicular References Cited by the Examiner UNITED STATES PATENTS 1,130,722 3/1915 Fletcher 52-356 X 1,327,741 1/1920 Shuman 52-243 X 1,446,916 2/1923 McElheny 52356 X 1,867,329 7/1932 Ryan 52241 X 3,012,525 12/1961 Thomas, Sr. et 'al 99 3,089,284 5/1963 Heuer 52599 FRANK L. ABBOTT, Primary Examiner. A. C. PERHAM, A sistant Examiner. 

1. A NONACID REFRACTORY SHAPE HAVING A FLAT SURFACE AND A METAL REINFORCEMENT COMPRISING: (A) A GENERALLY U-SHAPED CHANNEL HAVING (B) A FLAT WEB AND (C) TWO SIDE FLANGES, AND (D) A PLURALITY OF ARMS EXTENDING OUTWARDLY FROM SAID WEB AND STRUCK FROM SAID FLANGES, EACH OF SAID ARMS HAVING (E) A FLAT BASE LYING IN THE PLANE OF THE WEB, AND (F) A SHOULDER DISPOSED IN THE SAME DIRECTION AS THE FLANGES, THE PANEL OF THE WEB OF THE METAL REINFORCEMENT LYING IN THE PLANE OF THE FLAT SURFACE OF THE REFRACTORY SHAPE, AND THE FLANGES OF THE U-SHAPED CHANNEL AND THE SHOULDERS OF THE ARMS BEING EMBEDDED IN THE REFRACTORY SHAPE. 